I'm thinking of using an Explorer transfer box in a custom build off road
competition vehicle. I have an opportunity to purchase a T-box here in the
UK but like all UK Explorer T-boxes it has the electronic shift between Hi &
Low. Would it be possible to convert to a mechanical shift? Or would I have
to figure out the basic wiring to make the electrics work? Chances are I
would only ever need 4X4 low in my custom build. Could I ignore all the
other wires and multi plugs on the T-box for a purely mechanical, no warning
light, no ARC, no frills application? The transfer box would be the only
Explorer item in the build but it would easily cope with the 150 BHP that I
intend putting through it.

"Simon H" <simonh@deadmailbox.com> wrote in message
news:d348ir$i9l$1@titan.btinternet.com...
> I'm thinking of using an Explorer transfer box in a custom build off road
> competition vehicle.

You didn't say what year the box was from. If I understand correctly you
only want to get it into 4 Low and keep it there? On the 91-94 all you have
to do is remove the servo motor from the transfer case and turn it by hand
to the 4L position (with transmission in neutral). But if you are building
a custom vehicle I'd think you'd know that so I must be missing
something....

"Ulysses" <therealulysses@yahoo.com> wrote in message
news:115ebu5lsuse670@corp.supernews.com...
>
> "Simon H" <simonh@deadmailbox.com> wrote in message
> news:d348ir$i9l$1@titan.btinternet.com...
>> I'm thinking of using an Explorer transfer box in a custom build off road
>> competition vehicle.
>
> You didn't say what year the box was from. If I understand correctly you
> only want to get it into 4 Low and keep it there? On the 91-94 all you
> have
> to do is remove the servo motor from the transfer case and turn it by hand
> to the 4L position (with transmission in neutral). But if you are
> building
> a custom vehicle I'd think you'd know that so I must be missing
> something....
>
Thanks for the reply!
Most custom builds over here in the UK are Land Rover or Range Rover based
as they are by far the most common suitable donor vehicles so using Ex stuff
is a break from the norm.
I guessed that I could maunually set it into 4X4 low and somehow lock it
there, but what concerns me about the Explorer T-box are all the wires and
plugs hanging out of it! Am I right in thinking that the servo motor is the
only electrical CONTROL for the box? Are any of the other wires and gizmos
needed to actually make the box work? Or are they just for warning lights
and other 'trivial' stuff?

"Simon H" <simonh@deadmailbox.com> wrote in message
news:d38775$hr1$1@hercules.btinternet.com...
>
> Thanks for the reply!
> Most custom builds over here in the UK are Land Rover or Range Rover based
> as they are by far the most common suitable donor vehicles so using Ex
stuff
> is a break from the norm.
> I guessed that I could maunually set it into 4X4 low and somehow lock it
> there, but what concerns me about the Explorer T-box are all the wires and
> plugs hanging out of it! Am I right in thinking that the servo motor is
the
> only electrical CONTROL for the box? Are any of the other wires and gizmos
> needed to actually make the box work? Or are they just for warning lights
> and other 'trivial' stuff?
>
> Cheers
> Simon H
>

I can only speak for the older Explorers (91-94) but some of the wires are
for dash indicators. If you were to remove the servo motor and manually
move the transfer case to 4L I think it would stay put without having to
lock it in place. Of course you would not be able to reattach the servo
motor unless you moved it to the 4L position also. Some kind of cover would
be needed to protect the transfer case from dirt etc.

I don't know what ALL of the wires are for. There is also a sensor that
plugs into the transfer case that is held in place mainly by the servo motor
bracket. I'm not sure what that sensor is for but I'm pretty sure it is not
to detect the gear positions. Maybe it's for fluid level or pressure.
Someone else here probably knows. I had to remove the servo motor when it
got stuck so I could engage 4WD and the transfer case indeed engaged but the
dash indicators did not come on. I'm pretty sure the indicators are
controlled by the servo motor position.
>

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